Tubing Retrievable Injection Valve Assembly

ABSTRACT

A method and apparatus for controlling the flow of fluid in an injection well includes a main valve assembly having a valve and a retrievable nozzle selective lock assembly (RNSLA). The RNSLA is operable when positioned within the valve body to open the valve when fluid is pumped into the well and closes the valve when fluid flow is terminated. The RNSLA includes a replaceable orifice nozzle so that orifices of different dimensions may be used in conjunction with the valve assembly. In an alternate embodiment, the RNSLA includes a variable output nozzle assembly to maintain the valve in a protected open position without chattering over a wide range of flow rates.

This application is a continuation of U.S. patent application Ser. No.15/714,105 filed Sep. 25, 2017 which is a continuation of U.S. patentapplication Ser. No. 15/099,286 filed Apr. 14, 2016 which is acontinuation application of Ser. No. 13/669,059 filed Nov. 5, 2012 whichclaims priority to provisional application Ser. No. 61/639,569 with afiling date of Apr. 27, 2012, all of which are incorporated by referenceherein in their entirety.

BACKGROUND OF INVENTION 1. Field of the Invention

This invention is directed to an injection valve typically used inconjunction with an injection well. Injection wells are drilled forexample in close proximity to producing oil or gas wells that havepeaked in terms of their output. Fluid for example water is pumped underpressure into the injection well which in turn acts to force the oil orgas into the producing wells thus increasing the yield.

2. Description of Related Art

U.S. Pat. No. 7,866,401 discloses an injection safety valve having arestrictor to create a pressure differential so as to move a flow tubepast a flapper valve. The diameter of the restrictor is fixed.

BRIEF SUMMARY OF THE INVENTION

The invention includes providing a tubing retrievable injection valvehaving a full bore internal diameter when running and retrieving thevalve. A slick line retrievable nozzle having an orifice is carried by aretrievable nozzle selective lock assembly. The nozzle assembly isretrievable without removing the injection valve. Consequently thediameter of the nozzle may be changed on the surface. The injectionvalve also has a temporary lock out feature so that the valve may beplaced in the well in a lock out mode. In certain situations where theflow rate of the water may vary, an embodiment of the invention includesa nozzle assembly with a variable orifice to provide an infinitelyvariable downhole nozzle that will minimize the pressure drop duringinjection over a range of injection flow rates. The nozzle is designedto generate a pressure drop sufficient to hold the flapper valve fullyopen. This prevents the flapper valve from “chattering” and isolates theflapper valve from fluid flow during injection both of which are harmfulto the flapper valve assembly.

The variable output nozzles are designed so that as flow occurs, theflow tube will first move in a direction to open the flapper valve andthen the output area of the nozzle will increase with increased flowrates.

The nozzle assembly can either be run pre-installed in the injectionvalve prior to running or after the injection valve has been set,utilizing wireline/slickline operations to insert and or remove thenozzle assembly from the injection valve.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a cross sectional view of an embodiment of the valve in a lockout, running position.

FIG. 2 is a cross sectional view of an embodiment of the valve in apre-injection position with the valve member closed.

FIG. 3 is a cross-sectional view of the retrievable orifice selectivelock assembly.

FIG. 4 is a perspective view of the retrievable nozzle selective lockassembly.

FIG. 5 is a cross sectional view of a valve showing the retrievablenozzle selective lock assembly located within the valve body.

FIG. 6 is a cross sectional view of a valve in an open injectionposition.

FIG. 7 is a cross-sectional view of a second embodiment of a retrievablenozzle selection lock assembly according to the invention.

FIG. 8 is a cross-sectional view of the embodiment of FIG. 7 shown in afully open condition.

FIG. 9 is a cross-sectional view of a third embodiment of a retrievablenozzle selective lock assembly according to the invention.

FIG. 10 is a cross-section view along line 10-10 of FIG. 11 of a fourthembodiment of a retrievable nozzle selective lock assembly according tothe invention.

FIG. 11 is an end view of the retrievable nozzle assembly of FIG. 10.

FIG. 12 is a cross-sectional view of the nozzle core member of theembodiment of FIG. 10.

FIG. 13 is a cross-sectional view of an embodiment of the valveaccording to the invention with the variable nozzle assembly of theembodiment shown in FIG. 10 I the closed position.

FIG. 14 is a cross-sectional view of the embodiment shown in FIG. 13with the flapper valve in the open position.

FIG. 15 is a cross-sectional view of the embodiment shown in FIG. 13with the flapper valve in the open position and the variable orifice inthe open position.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an embodiment of the injection valve 10 includes apressure containing body comprising an upper valve body member 11, atubular middle valve body member 12 suitably attached to the upper valvebody member 11 by threads at 29, for example, and a lower valve bodymember 13 which is connectable to a tubular at its downhole end. Valvebody members 12 and 13 are secured to each other by threads for exampleat 34.

The injection valve 10 further includes an upper flow tube having afirst section 17 and a second section 19 which are secured together.Section 17 has an interior nipple profile at 16 for receiving a tool.Second section 19 extends to valve seat 26 when the valve is in theposition shown in FIG. 1. Second section 19 includes a plurality ofslots 32 as shown in FIG. 1. Ridges 33 are formed on the inner surfaceof second section 19 around slots 32 thus forming a collet. A shiftablelower flow tube 31 is positioned within the elongated sleeve portion 19of the upper flow tube. Shiftable lower flow tube 31 has two annulargrooves 35 and 36 on its outer periphery located so as to form a profilefor engagement with ridges 33 on the inner surface of second section 19.Shiftable flow tube 31 also has shifting profiles 39 and 38 at each endthereof.

Middle body member 12 has a reduced diameter portion 25 that carries anannular valve seat 26. A flapper valve 27 is pivotably connected at 28to valve seat 26 and is resiliently biased to a closed position on valveseat 26 as is known in the art.

A coil spring 18 is positioned about second section 19 and is capturedbetween shoulder 14 of the upper flow tube and an internal shoulder 41provided within middle valve body member 12.

In the temporary lock out running position shown in FIG. 1, shiftableflow tube 31 is positioned within the valve body so as to extend beyondvalve seat 26 thereby maintaining flapper valve 27 in an open position.

When the valve is positioned within the well at the desired location, asuitable running tool is lowered into the well and engages the uppershifting profile 39 of shiftable flow tube 31 and the flow tube is movedupwardly, to the position shown in FIG. 2. The uphole end portion 91 ofthe shiftable lower flow tube 31 will abut a shoulder portion 92 of theupper flow tube 15 as shown in FIG. 2. In this position, the resilientlybiased flapper valve will be in the closed position.

The retrievable nozzle selective lock assembly (RNSLA) will now bediscussed with reference to FIGS. 3 and 4. The RNSLA 50 includes asleeve formed by generally cylindrical members 51, 52, and 53 having aninterior flow passage 61. An inner tubular member 56 is located withincylindrical member 52 and carries nozzle 53. A plurality of selectivelocking dogs 58 are located around a portion of its periphery as shownin FIG. 4. Leaf springs 59 are positioned under locking dogs 58. RNSLA50 includes an annular packing assembly 55. A replaceable andretrievable orifice nozzle 53 is releaseably attached to the bodyportion of the RNSLA and includes an orifice 54. Nozzle 53 may bereplaced on the surface with another nozzle having a different sizeorifice 54.

FIG. 5 illustrates the position of the RNSLA within the injection valveprior to the injection stage. RNSLA may be lowered into the valve bodyby a suitable tool to a position where the selective locking dogs 58engage the selective nipple profile 16 in first section 17. At thispoint the RNSLA will be physically connected to the upper flow tube;however flapper valve 27 is still in the closed position.

The next step in the process is to pump a fluid such as water underpressure into the valve body. As the fluid flows through the RNSLA, apressure drop will occur across orifice 54 which will cause the RNSLAand the upper flow tube as well as shiftable flow tube 31 to movedownhole as shown in FIG. 6.

This movement will compress spring 18. The downhole portions of both theupper flow tube and lower flow tube will be forced into contact withflapper valve 27 and as they are moved further by the pressuredifferential, they will open the flapper valve to the position as shownin FIG. 6.

As long as the fluid is being pumped the injection valve will remainopen. However when the pumping stops, compressed spring 18 will move theRNSLA and the upper and lower flow tubes back to the position shown inFIG. 5 in which the flapper valve is in the closed position.

FIG. 7 illustrates a second embodiment of the invention. In this case avariable output nozzle assembly 100 replaces the nozzle 53 shown inFIGS. 3 and 4.

Variable output nozzle assembly 100 includes an outer tubularcylindrical casing 101. An axially moveable cylindrical sleeve 103having an enlarged portion 107 is positioned within casing 101 and hasan end face 114 that extends outwardly of casing 101. Sleeve 103 has aninterior flow passage 105 and also has a plurality of outlet ports 104that are axially and radially spaced about its longitudinal axis. Sleeve103 terminates in an end face 116 that includes an outlet orifice 115. Acoil spring 102 is positioned between the inner surface of casing 101and the outer surface of sleeve 103 as shown in FIG. 7. In the relaxedposition of FIG. 7, one end of the coil spring 102 abuts againstshoulder 108 on enlarged portion 107 of sleeve 103 and the other endabuts against end face 109 of the casing 101.

At lower flow rates, the pressure drops across orifice 115 will besufficient to move the lower flow tube to a position keeping flappervalve 27 open. As the flow rate increases, sleeve 103 is moved axiallyto sequentially move outlet ports 104 past the end face 109 of casing101 as shown in FIG. 8, thereby allowing more fluid to exit the nozzleto proceed downhole of the flapper valve.

FIG. 9 illustrates a variation from the shape and location of the outletports. In this embodiment outlet ports may be relatively large circularopenings 114 that are axially offset with respect to one another.Openings 114 may also be elliptical or wedged shape or of any geometricshape.

The spring constants of springs 18 and 102 are chosen so that as fluidflow begins, the RNSLA will first move in a downhole direction openingthe flapper valve before sleeve 103 moves in a downhole direction.

FIGS. 10-12 illustrate yet a further embodiment of the invention.

In this embodiment the variable output nozzle assembly includes a firstfixed portion including a cylindrical tubular casing 124 having a solidconical core member 139 supported therein by a plurality of struts 129as shown in FIGS. 11 and 12. An outer tubular sleeve member 120 isfitted over casing 124 and includes a constricted portion 122 andconical portions 131 and 132 on either side of constricted portion 122.Conical member 139 has a first enlarged portion 130 followed by atapered cone portion 123. Outer sleeve member 120 includes a thin walledportion 121 that extends to an annular shoulder 126 such that an annularspace 133 is formed between casing 124 and thin walled portion 121. Acoil spring 125 is positioned within space 133 such that one end of thespring abuts against a shoulder 134 on enlarged portion 126 of thinwalled portion 121 and abuts against a shoulder 135 provided on tubularcasing 124. Thin wall portion 121 is detachably secured to outer sleevemember 12 at 140 for example by threads. In the position shown in FIG.10, the outer surface of core member 139 engages constriction 122 so asto prevent flow.

As the flow rate of fluid is increased, outer sleeve member 120 willmove to the right as viewed in FIG. 10. Due to the tapering of conesection 123, the outlet area of the nozzle at 122 will increase as theflow rate increases. Thus at lower flow rates sufficient force will beprovided to maintain the flapper valve in the open position as well asat high flow rates.

The embodiments according to FIGS. 7-12 provide an infinitely variablenozzle which will minimize pressure drop over a range of injection flowrates. They provide full open flapper protection over the full range ofinjection rates thus eliminating flapper chatter due to partial valveopening during injection.

The variable output nozzles of FIGS. 7-12 can be substituted for thenozzle 53 shown in FIG. 3 so that they can be placed and retrieved as apart of the RNSLA shown in FIGS. 3 and 4.

FIGS. 13-15 shown the sequential opening of the flapper valve and thevariable orifice as flow is initiated in the well according to theembodiment of the variable orifice shown in FIG. 10. The differencebetween FIGS. 5 and 6 and FIGS. 13-15 is that the nozzle assembly 53 ofFIGS. 5 and 6 has been replaced by the nozzle assembly of FIG. 10.

In the position shown in FIG. 13, the flapper valve 27 is closed and theouter surface of core member 139 engages constriction 122 so as toprevent flow through the nozzle. The lower ends of upper flow tube 10and lower flow tube 31 are positioned adjacent the flapper valve 27. Asfluid flow begins the upper and lower flow tubes along with the variableorifice nozzle assembly will move downwardly due to fluid pressurethereby comprising spring 18. The spring constants for spring 18 anspring 125 are selected so that during initial fluid flow the upper andlower flow tube as well as the variable orifice nozzle assembly willmove to the position shown in FIG. 4 with the variable orifice 122 stillin a closed position. However, as fluid pressure and flow increases,outer sleeve member 120 will move downwardly with respect to tubularcasing 124 in which cone member 139 is fixed to the position shown inFIG. 15. In this position fluid will flow through variable orifice 122.

All of the embodiments may be deployed or retrieved using a wireline orslickline and are easily redressable and repairable. Furthermore, wheninjection flow is stopped the valve automatically will close, therebyprotecting the upper completion from back flow or a blowout condition.

Although the present invention has been described with respect tospecific details, it is not intended that such details should beregarded as limitations on the scope of the invention, except to theextent that they are included in the accompanying claims.

I claim:
 1. A valve assembly for controlling the flow of fluid within aninjection well comprising: a valve body, an axially movable flow tubewithin the body, said flow tube having an upper and lower portion aflapper valve located at a downhole end of the valve body, and avariable restrictor positioned within the valve body and operable toopen the flapper valve when fluid flow is initiated through the valvebody and operable to close the flapper valve when fluid flow isterminated, said variable restrictor being in a closed condition at afirst flow rate to open the flapper valve and being open at a secondhigher flow rate to allow fluid flow through the valve assembly.
 2. Thevalve assembly of claim 1 wherein said variable restrictor may beretrieved from the injection well while leaving said flapper valve inthe well in a closed position.
 3. The valve assembly of claim 2 whereinsaid flow tube is adapted to be shifted to a first position to lock thevalve assembly in an open position.
 4. The valve assembly of claim 1further including a spring, the spring being compressed by axiallymovement of the flow tube.
 5. A valve assembly as claimed in claim 1wherein the variable restrictor includes a variable orifice.
 6. A valveassembly as claimed in claim 5 wherein the variable orifice comprises anouter tubular casing and an axially movable sleeve positioned within theouter casing, said axially movable sleeve having an internal flowpassage and a plurality axially spaced outlet ports.